Record DFA 127 User manual

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Technical Manual
DFA Battery Backup
Weight 1.25KG
Dimensions = 160mm wide x 80mm high x 125mm deep

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Manufacturer’s Declaration of Conformity (CE)
Record UK
Unit D, 9 Watt Place
Hamilton International Park
Blantyre
G72 0AH
The Manufacturer Certifies That;
Product: DFA 127 Battery Backup
Description: Automatic Door Control Equipment
This Equipment is designed to be incorporated into an automatic door set, not to be used independently and must not be
“put into service” until the complete door set has been declared compliant to the EC Machine Directive.
Conforms to the protection requirements of the following directives.
2006/95/EEC (Low Voltage Directive) LVD
89-336 EEC (Electromagnetic Compatibility) EMC
2006/42/EC (Machine Directive)

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CAUTION
AN INADEQUATELY INSTALLED AND ADJUSTED DOOR COULD CAUSE DAMAGE TO THE EQUIPMENT AND MAY CAUSE
INJURY TO OTHERS.
HAVE YOUR DOOR PERIODICALLY INSPECTED & SERVICED AT LEAST TWICE PER
YEAR BY AN ADSA (Automatic Door Suppliers Association) CERTIFIED TECHNICIAN.
THIS DOOR IS NOT INTENDED TO BE DISCONNECTED FROM THE MAINS AT NIGHT!
Introduction
This manual contains all the information you may require to install, maintain and service your Battery backup
system.
The System allows a DFA 127 Swing Door Operator to be used even during mains power fail situations.
Safety
Your door system has been manufactured to the latest applicable safety standards; in order for you to comply you will
need to have the door installed to any relevant safety standards by a qualified engineer.
Any “Danger Areas” of the door set must be indentified and protected. Examples of protection are safety sensor and
barriers to prevent persons /objects entering these areas.
The manufacturer recommends that the door complies with the BS EN 16005 as a minimum but, may need to comply
with other standards such as: Part M, Building Regulations, The Machine Directive and / or Disability Discrimination Act.
Please consult the relevant professional bodies for details.
Environmental Requirements
The DFA Battery Backup contains electronics and batteries that may have materials that could be hazardous to the
environment. Please remove these products and dispose of them safely, in accordance with the laws of your country,
when the operator is decommissioned.
Intended Use
Internal use only –Not to be installed externally
Only for use with the record DFA 127 Swing Door Operator

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The DFA Battery Backup comes complete in its own housing and at just 16cm long it is a small but powerful battery unit.
The case is aluminum “stainless steel” effect and looks seamless against the standard DFA 127 Swing Unit.
It can be fitted anywhere within 1 metre of the control unit. We recommend fitting it directly next to the existing operator
for aesthetics.
You can fix it next to the current swing unit as a separate module or you can modify the casing for a more streamlined
look.
If fitting to the side with the existing rocker switch you will need to purchase an extended ribbon cable
NEVER PLUG THE BATTERY UNIT IN OR OUT OF YOUR SWING DOOR
OPERATOR WITH THE MAINS ON –ALWAYS ISOLATE THE SPUR FIRST
BLACK AND WHITE CABLE TO THE STG
BLACK AND RED TO THE PSU

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1. Remove the cover, end-caps and battery unit from the back plate
2. Fix the unit next to the DFA 127 swing door operator
3. Re-fit the end-caps and battery unit
4. Route your cables to the swing unit by drilling through the end-caps or via any hollow
path with the frame.

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5. Output –Fly lead plugs into the control unit of your DFA 127(J)
6. Input –Fly lead plugs directly on to the PSU, under the plastic cover. (I)
For a more streamlined look –Cut 8mm off of the back plate and Install as previous but with just
the outside end-cap.
It may look slightly odd but when the cover is installed as below it gives a seamless connection.

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The cover is push fit –Please feel free to add additional fixings or fasteners as site conditions dictate.
The Battery Unit has two functions:
A) Continuous use upon mains failure
Or
B) To hold the door open upon mains failure
For Option A –Continuous - you only need to turn on the Battery Backup by pressing the ON button once (A)
For Option B –You must wire from the relay on the Battery Unit to the SSK –When the mains fails the battery will take
over but also it will close the relay thus triggering the DFA to stand open.
See wiring diagram below - connecting the relay to the DFA 127.
Volume
When the mains supply has cut off the battery unit will take over in approximately 3 seconds.
Once this has happened the system will beep every 5 seconds to tell the customer that the mains has failed. You can
set the volume to: low, high or mute by moving the jumper up / down or removing it as below:

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Remote Activation (Discharge) Feature
A feature of this system is that once the battery unit is powering the swing door you can have the building management
system open the door upon impulse –commonly seen in smoke egress situations.
. To allow this function link LK1 must be removed. - discharge Link (G)
Using avolt free contact on pins 1 and 2. Leaving the connector open circuit will disable the battery.
Note : Using this function will not stop the battery from charging.
Wire a normally open circuit into discharge from your switch (5 amp) (D)
Now, whenever the building system connects the discharge pair –the battery unit is woken up and triggers the door to
open.

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TECHNICAL SPEC
Circuit Operation
The circuit acts as a battery backup for swinging doors. Existing designing have been large, power hungry
devices as they were required to convert the high voltage door operational voltage of 40V down to 12V or
24V and when required, back up to 40V. This required a step-down converter and a step-up converter.
With the advent of lithium technology an multicell balancing chips, this new circuit design allow the use of a
40V lithium pack. The advantage being, no voltage conversion is required. The circuit is designed to be
placed between the existing PSU and load/door controller.
The diagram below shows the simple operation that is required.

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Circuit Protection Overview
Battery Pack
◦The battery pack has a thermistor device attached to the cells to monitor any over temperature
that may arise from fast charging/discharging or damage cells
Resettable Fuse
◦The battery pack is protected with a 3.75A polyfuse.
Thermal
◦The power switching transistors that control the charge and discharge is monitored by a thermistor.
Over-Current
◦The charge and discharge current is limited to 3A using a current sense resistor.
Battery Balance
◦While the circuit detects an input supply the cells are permanently monitored and kept balanced.
Reverse Polarity
◦Input is protected against reverse polarity and will apply a short to the input to blow the fuse in
the PSU unit.
Regenerative Power
◦Power regenerated by the doors motors being manually operated, is absorbed.
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PSU Input
The PSU Input is supplied from a separate unit which has a toroidal transformer, rectifier, reservoir capacitor
and a two fuses, one glass 20mm fuse on the mains supply and a poly fuse on the low voltage side. The
supply can deliver 3A at 40V.
The circuit has two load resistors R32&R33 which help with the mains fail detect speed response due to the
reservoir capacitor on the PSU being so large.
Diode D3 protects from reverse polarity protection.
PSU Output
The output is supplied either by the input via D1&D2 or from the battery via F1,R31,TR4,TR5.
Isolation
The Output is separated from the input by D1 & D2, which is required to allow for mains fail detection.
R1 reduces ghosting voltages from the result of switching the ground supply.
Charger Control
The charge is controlled by TR5 which in turn is controlled by the balancer, which is then again controlled by
the processor. If charge is allowed then TR5 is switched on and current is allowed to flow through the body
Diode of TR4

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Discharge Control
The discharge is controlled by TR4 which in turn is controlled by the balancer, which is then again controlled
by the processor. If charge is allowed then TR4 is switched on and current is allowed to flow through the
body Diode of TR5
Current Sense
The sense resistor R31 is a 0.05R resistor, when 200mV is sensed across the resistor, then the balance
circuit will switch off the charge transistors. C22,23,24 & R27,28 are smoothing components for a more
average reading.
Cell Balancer
The cell balancer is a Texas Instruments BQ76930 10 cell balancer. It has two identical circuits inside,
voltage level shifted to share 5 cells a piece.
Via I2C, the processor controller can use the bq76930 to implement many battery pack management
functions, such as monitoring (cell voltages, pack current, pack temperatures), protection (controlling
charge/discharge FETs), and balancing. Integrated A/D converters enable a purely digital readout of
critical system parameters.
For an additional degree of pack reliability, the bq76930 includes hardware protections for :
• Voltage
◦Over-Voltage per cell.
◦Under-Voltage per cell
• Current
◦Over-Current Detection
◦Short-Circuit Detection
Buzzer
The buzzer is fitted with a link (LK2). The buzzer will operate on mains fail, producing a short pulse every 5s.
The volume can be adjusted with the link. Choices of volume are low/high/off.
Micro-Controller
The micro-controller is required to communicate with the cell balancer, read voltages and control relays. It's
main functions are as follows
• Sets voltage and current limits, for battery pack.
• Monitors temperature of battery pack and power switches.
• Detects mains presence.
• Drives buzzer.
• Controls Charge and Discharge switches.
Mains Fail Relay
The board is fitted with a volt free NO/NC/COM relay connection (PL6). As soon as the input reaches over
33V, the relay will energise. The relay coil is rated up to 50V DC. Due to the large reservoir capacitor on the
PSU which can take up to 40 seconds to discharge,
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BASIC FAULT FINDING
If battery is not operating :
1. Check power led is on.
2. Check voltage on battery is over 33V.
3. Make sure LK1 is ON or external contact on PL5 is shorted.

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If 'Enable battery discharge' is not operating, check link LK1 is removed.
If Buzzer is not sounding on mains fail, check link LK2 is fitted.